Method of applying an electric conductive layer to selected portions of a mounting frame

ABSTRACT

A foam mount of an aircraft window has a groove to receive an electro chromic window. The foam mount is painted by placing a blank in the groove to divide the foam mount into a first section designated to face the exterior of the aircraft and an opposite second section. The groove and the first section are coated with an electric conductive paint, and the second section is covered with a decorative paint. The conductive coating on the foam mount and the conductive coating of the electrodes of the electro chromic window provide an RF shielding to prevent electronic signals from personal electronic equipment from passing through the cabin and door windows of the aircraft. A mask is also provided to coat one section of the foam mount while covering the other section.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No. 12/402,709filed Mar. 12, 2009, which application is herein incorporated byreference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a method of applying an electric conductivelayer to selected portions of a mounting frame or foam mount, and to thefoam mount, and more particularly, to applying the electric conductivelayer to inner surface of one side of the foam mount, and applying anon-electric conductive layer to inner surface of opposite side of thefoam mount.

2. Discussion of the Technical Problem

At the present time there is a desire to provide electronic shieldingaround the body of commercial aircrafts such that electronic signals toand from electronic equipment of the passengers, e.g. cell phones andcomputers within the commercial aircraft, are only transmitted by andreceived through the antenna of the aircraft. One of the advantages ofthis arrangement is the elimination of uncontrolled transmission ofsignals through the windows of the aircraft, which transmitted signalscan interfere with transmitted signals required to operate the aircraft.As is appreciated by those skilled in the art, to attain this goal itbecomes necessary to prevent transmission of the signals through thecabin windows and through the door windows of the aircraft.

In one approach to accomplish this goal, a window pane having anelectric conductive layer is mounted in a foam mount having an electricconductive layer. The window pane can be an electro-chromic window, orone or more glass sheets having an electric conductive layer or filmover the major surface of one or more of the sheets. More particularlyand as is known in the art, the electro chromic window includes anelectro chromic medium between two spaced electrodes. Each of theelectrodes include an electric conductive layer or film on a majorsurface of a glass sheet. The electric conductive layer or film providesa radio frequency (“RF”) shielding.

The outboard surface of the foam mount has an electric conductive layer,e.g. an RF shielding layer or coating. The inboard surface of the foammount is coated with a non-electrical conductive decorative paint tocompliment the décor of the aircraft interior. The foam mount having thewindow pane is positioned in the window opening of the aircraft betweenan outboard structural ply and an inboard protective overlay sheet. Theconductive layer on the foam mount is electrically connected with theaircraft wall to connect the electric conductive layer of the foam mountto the electric ground of the aircraft. With this arrangement, theelectric conductive layers of the electro-chromic window and theelectric conductive layer of the foam mount provide an RF shielding overthe window opening in the body of the aircraft.

As is appreciated by those skilled in the art, applying two differentlayers, or coatings on a foam mount can be time consuming and laborintensive. It would be advantages, therefore, to provide a method ofcoating selected portions of a foam mount with an electric conductivelayer, and other selected portions of the foam mount with a non-electricconductive decorative layer that minimizes the time and the labor toapply the two layers to a foam mount.

SUMMARY OF THE INVENTION

This invention relates to a method of applying an electric conductivelayer to selected portions of a foam mount; the foam mount in a shapehaving an enclosed frame surrounding an open area. The frame in crosssection includes, among other things, a peripheral surface; an innersurface opposite to the peripheral surface, the inner surface definingthe open area; a first side extending from the peripheral surface tofirst portion of the inner surface, and an opposite second sideextending from the peripheral surface to second portion of the innersurface, wherein the inner surface of the foam mount includes open endof a groove facing the open area of the foam mount and the first portionis on one side of the open end of the groove and the second portion ison the other side of the open end of the groove. The method includes,among other things, applying a first electric conductive coating overinner surfaces of the groove; inserting peripheral edge of a substratein the groove to completely cover the open area of the foam mount toseparate the foam mount into a first section and a second section. Thefirst section includes the first side of the foam mount and a portion ofthe inner surface connected to the first side defined as a firstportion, and the second half includes the second side of the foam mount,and a portion of the inner surface connected to the second side definedas a second portion. A second electric conductive coating is appliedover the first section, wherein the coating on the first section and thecoating on the inner surface of the groove contact one another, and anon-electric conductive coating is applied over the second section ofthe foam mount.

Further, this invention relates to a method of making an RF shieldedwindow by, among other things, providing a foam mount in a shape havingan enclosed frame surrounding an open area, the frame in cross sectionhaving, among other things, a peripheral surface; an inner surfaceopposite to the peripheral surface, the inner surface defining the openarea; a first side extending from the peripheral surface to firstportion of the inner surface, and an opposite second side extending fromthe peripheral surface to second portion of the inner surface, whereinthe inner surface of the foam mount includes open end of a groove facingthe open area of the foam mount, and the first portion is on one side ofthe open end of the groove and the second portion is on the other sideof the open end of the groove. A transparency having an electricconductive layer over a major surface of the transparency is shaped andsized to fit within the groove of the foam mount and completely coverthe open area of the foam mount. A substrate having a peripheral shapeand a thickness similar to peripheral shape and thickness of thetransparency is provided. A first electric conductive coating is appliedover inner surfaces of the groove, afterward, peripheral edge of thesubstrate is inserted in the groove to completely cover the open area ofthe foam mount and to separate the foam mount into a first section and asecond section. The first section includes the first side and a portionthe inner surface connected to the first side defined as a firstportion, and the second half includes the second side, and a portion ofthe inner surface connected to the second side defined as a secondportion. A second electric conductive coating is applied over the firstsection, wherein the second coating on the first section of the foammount and the first coating on the inner surfaces of the groove contactone another. A non-electric conductive coating is applied over thesecond section of the foam mount. The substrate is removed from the foammount, and the transparency is placed in the groove of the foam mount.

Still further, this invention relates to an aircraft window mounted in afoam mount made by the above methods.

In addition, this invention relates to a coating mask including, amongother things, a base; a wall mounted on the base and extending upwardfrom the base; a first shim mounted on the base between perimeter of thebase and the upright wall; a second shim mounted on the base between theperimeter of the base and the wall, the first and the second shimsspaced from on another, and a cover mounted to the first shim to move ina first direction to a dosed position, wherein the cover in the closedposition is over the base and on the second shim, and to move the coverin an opposite second direction to an open position to expose surface ofthe base within the wall. The cover has an opening, which is sized suchthat when the cover is in the closed position, the cover overlays thewall and the base within the wall is viewed.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a fragmented side view of an aircraft showing outboard view ofa cabin window.

FIG. 2. Is a view taken along lines 2-2 of FIG. 1.

FIG. 3 is a cross sectional view of the foam mount shown in FIG. 2.

FIG. 4 is a plan elevated top view of a blank used in the practice ofthe invention to prevent coating overlap.

FIG. 5 is a prospective view of a mask in the open position; the maskcan be used in the practice of the invention to prevent coating overlap.

FIG. 6. Is a view similar to the view of FIG. 5 showing a foam mountpositioned on the base of the mask.

FIG. 7 is a view similar to the view of FIG. 6 showing the mask in theclosed position.

FIG. 8 is a fragmented side view of one non-limited embodiment of a maskcover on one side of the foam mount in accordance to the teachings ofthe invention.

FIG. 9 is a view similar to the view of FIG. 8 showing anothernon-limited embodiment of a mask cover on the other side of the foammount in accordance to the teachings of the invention.

DESCRIPTION OF THE INVENTION

As used herein, spatial or directional terms, such as “inner”, “outer”,“left”, “right”, “up”, “down”, “horizontal”, “vertical”, and the like,relate to the invention as it is shown in the drawing figures. However,it is to be understood that the invention can assume various alternativeorientations and, accordingly, such terms are not to be considered aslimiting. Further, all numbers expressing dimensions, physicalcharacteristics, and so forth, used in the specification and claims areto be understood as being modified in all instances by the term “about”.Accordingly, unless indicated to the contrary, the numerical values setforth in the following specification and claims can vary depending uponthe desired properties sought to be obtained by the present invention.At the very least, and not as an attempt to limit the application of thedoctrine of equivalents to the scope of the claims, each numericalparameter should at least be construed in light of the number ofreported significant digits and by applying ordinary roundingtechniques. Moreover, all ranges disclosed herein are to be understoodto encompass any and all subranges subsumed therein. For example, astated range of “1 to 10” should be considered to include any and allsubranges between (and inclusive of) the minimum value of 1 and themaximum value of 10; that is, all subranges beginning with a minimumvalue of 1 or more and ending with a maximum value of 10 or less, e.g.,1 to 6.7, or 3.2 to 8.1, or 5.5 to 10. Also, as used herein, the terms“sprayed over”, “applied over”, or “provided over” mean sprayed,applied, or provided on but not necessarily in surface contact with. Forexample, a material “applied over” a substrate does not preclude thepresence of one or more other materials of the same or differentcomposition located between the deposited material and the substrate.

Before discussing non-limiting embodiments of the invention, it isunderstood that the invention is not limited in its application to thedetails of the particular non-limiting embodiments shown and discussedherein since the invention is capable of other embodiments. Further, theterminology used herein to discuss the invention is for the purpose ofdescription and is not of limitation. Still further, unless indicatedotherwise in the following discussion, like numbers refer to likeelements.

Non-limiting embodiments of the invention will be directed to thepractice of the invention to make a cabin window of an aircraft; theinvention, however, is not limited to any particular type of aircraftcabin window, and the invention contemplates the practice of theinvention on door windows of an aircraft. Further, the invention can bepracticed on windows for commercial and residential buildings, e.g. butnot limited to type disclosed in U.S. Pat. No. 5,675,944, which patentin its entirety is hereby incorporated by reference; on a window for anytype of vehicle; e.g. air and space vehicles, and above or below watervessels, and on a window for a viewing side or door for any type ofcontainers, for example but not limited to a refrigerator, cabinetand/or oven door.

With reference to FIGS. 1 and 2 as needed, a section 20 of an aircraft22 has a cabin window 24. The cabin window 24 (see FIG. 2) includes aframe mount 26, which includes features of the invention and is coatedaccording to the invention. In the preferred practice of the inventionthe frame mount 26 is made of foam and will hereinafter also be referredto as “frame mount” or “foam mount.” A pane 28, e.g. an electro-chromicwindow 28 is mounted in a groove 30 of the foam mount 26. Theelectro-chromic window 28 includes an electro-chromic medium 31 betweena pair of electrodes 32 and 33. Each of the electrodes 32 and 33includes an electric conductive layer or film 34 on inner surface 35 ofa glass sheet 36. The marginal edges 37 of the sheets 36 of theelectrodes 32 and 33 are sealed to provide a sealed cell 38 having theelectro-chromic medium 31. Outer surface 39 of the glass sheet 36 of theelectrode 32 faces the exterior of the aircraft 22, and outer surface 40of the glass sheet 36 of the electrode 33 faces the interior of theaircraft 22. Electro-chromic windows are well known in the art and nofurther discussion of the construction of the electro-chromic window 24is deemed necessary.

The electro conductive film 34 of the electrodes 32 and 33 provides anRF shielding to prevent transmission of electric signals through thepane 28. The inboard inner surface 41 of the foam mount 26 faces theinterior of the aircraft 22, and outboard inner surface 42 of the foammount 26 faces the exterior of the aircraft 22. An inboard protectiveoverlay sheet 43 is between inboard side 44 of the foam mount 26 andinterior window frame 46, and a structural ply 48 is between outboardside 60 of the foam mount 26 and body 52 of the aircraft 22. Optionallya gasket 54 is provided between outboard surface 56 of the structuralply 48 and the body 52 of the aircraft 22 to minimize, if not eliminate,the ingress of moisture between the aircraft body 52 and the structuralply 48.

The invention is not limited to the manner in which, or the componentsused, to securely mount the cabin window 24 in the aircraft body 52, andany of the techniques or fasteners, e.g. bolts, nuts, screws, clips andlatches known in the art can be used in the practice of the invention tosecure the cabin window 24 to the aircraft body. As is appreciated bythose skilled in the art, the manner of using the fasteners, and thetype of fasteners used, to secure the cabin window to the aircraft body52 is dictated by the designer and/or builder of the aircraft and istherefore not limiting to the invention. Further, the inventioncontemplates unitizing the components of the cabin window, e.g. thestructural ply 48, the foam mount 26 having the pane 28, and the inboardprotective layer 24, and securing the unitized cabin window in theaircraft body 52, and thereafter securing the inboard window frame 46 tothe aircraft body. The invention also contemplates individually mountingand securing the components of the cabin window 24 in the aircraft body52, e.g. securing the structural ply 56 and gasket 54, if used, inposition; securing the frame mount 26 having the pane 28 in positionagainst the structural ply 48, and securing the inboard protective sheet42 in position against the frame mount 26, and thereafter, securing theinboard window frame 46 to the aircraft body.

The structural ply 48 is not limited to the invention and can be asingle glass or plastic sheet, or a pair of glass and plastic sheets,and combinations thereof laminated together by a interlayer material asis known in the art, e.g. as described in U.S. Patent ApplicationPublication 2007/0002422A1. When the sheets are made of glass, the glassis preferably chemically tempered, heat tempered or heat strengthen. Thematerials of the sheets and the number of sheets of the structural ply48 is not limiting to the invention.

The inboard protective overly sheet 43 is not limiting to the inventionand can be any of the types used in the art, e.g. a plastic sheet toprotect the underlying pane 28 from surface scratches caused bypassenger curiosity, cleaning solutions, and/or abrasive cleaningmaterials.

In the preferred practice of the invention, the pane 28 is an electrochromic device or window 28 having the medium 31 changing percent oflight transmission as a function of changes in voltage applied to themedium. The invention is not limited to the construction of the electrochromic window and any of the types known in the art, e.g. U.S. Pat.Nos. 5,215,821; 6,471,360 and 6,783,099 and U.S. Patent ApplicationPublication 2007/0002422A1 can be used in the practice of the invention.The invention also contemplates the pane 28 being a photo chromic devicehaving a pair of glass sheets spaced from one another and a mediumbetween the sheets that changes percent of light transmission as afunction of light intensity on the medium. The invention is not limitedto the construction of the photo chromic window and any of the typesknown in the art, e.g. U.S. Pat. Nos. 4,720,350; 5,973,039 and 7,393,101can be used in the practice of the invention. The invention furthercontemplates the pane 28 being a glass or plastic sheet, or one or moreglass or plastic sheets or combinations thereof, laminated together orspaced from one another by a spacer frame, e.g. of the type disclosed inU.S. Pat. No. 5,675,944. The above mentioned documents are herebyincorporated by reference.

As can now be appreciated by those skilled in the art, the inventioncontemplates the window 28 having an electric conductive layer or filmon at least one of the major surfaces of the window to act as an RFshielding. For example and not limiting to the invention, in theinstance when the window 28 is a photo chromic window, an electricconductive layer or film is provided on the outer surface of a sheet, orthe inner surface of a sheet, e.g. the surface 35 of the glass sheet 36of the electrode 32 and/or 33.

In another non-limiting embodiment of the invention, the pane 28includes a substrate, e.g. a glass or plastic sheet having anelectrically conductive layer or film over a major surface of thesubstrate. The electric conductive layer or film, e.g. the electricconductive layer 34 of the electrodes 32 and 33 of the pane 28 (see FIG.2) provides a barrier to the transmission of electronic signals, e.g.but not limited to signals received and transmitted by electronicequipment, e.g. but not limited to cell phones and wireless computers.The invention is not limited to the conductive layer 36, and the layercan be any of the types known in the art. Non-limiting embodiments ofconductive coatings that can be used in the practice of the inventioninclude, but are not limited to, a pyrolytic deposited fluorine dopedtin oxide film of the type sold by PPG Industries, Inc. under theregistered trademark NESA®; a magnetron sputter deposited tin dopedindium oxide film of the type sold by PPG Industries, Inc under theregistered trademark NESATRON®; a coating made up of one or moremagnetron sputter deposited films, the films including, but not limitedto a metal film, e.g. silver between metal oxide films (dielectricfilms), e.g. zinc oxide and/or zinc stannate, each of which may beapplied sequentially by magnetron spattering, e.g. as disclosed in U.S.Pat. Nos. 4,610,771; 4,806,220 and 5,821,001, the disclosures of whichare hereby incorporated by reference.

The foam mount 26 can be made of any material that is compressible,flexible and is electrically non-conductive. The material is preferablycompressible and flexible so that the pane 28 can be mounted in thegroove 30 of the foam mount 26. The foam mount 26 is electricallynon-conductive in order that only selected surface portions of the foammount can be made electrically conductive by an application of anelectrically conductive coating. More particularly and with reference toFIGS. 2 and 3 as needed, in one non-limiting embodiment of theinvention, an electrically conductive layer or coating 60 is applied orprovided over inner walls 61 of the groove 30, the outboard side 50, andthe outboard inner surface 42 of the foam mount 26, and a decorativecoating 62, preferably a non-electric conductive coating, is applied orprovided over the inboard inner surface 41 of the foam mount 26. Outerperipheral surface 64 of the foam mount 26 is not intentionally coveredwith either the conductive coating 62, or with the decorative coating62, because the outer surface 64 of the foam mount 26 is not visiblewhen viewing through the cabin window and not coating the surface 64realizes a reduction in the cost of the coatings; however, overspray orover paint onto the outer surface 64 of the foam mount is acceptable. Inone non-limiting embodiment of the invention, the invention waspracticed on Zote Foam mounts made by Technifab, Inc having an office inAvon, Ohio.

In the practice of the invention, the foam mount 26 is coated with theelectric conductive layers 60 and 61 to prevent electronic signals frommoving through the foam mount. The inboard inner surface 38 of the foammount is painted with a decorative paint for aesthetic reasons. Withreference to FIG. 3, interface 63 is the end of the conductive layer 61and the beginning of the decorative coating 62. As is appreciated, theinvention is not limited to the location of the interface 63; however,the conductive layers 60 and 61 and the conductive layer of the pane 28should provide an RF shielding without any gaps or separations betweenthe conductive layers 60 and 61 of the foam mount and conductive layerof the pane 28. Further, as is appreciated, the invention is not limitedto the types of paint used in the practice of the invention. In onenon-limiting embodiment of the invention, the electrically conductivecoating 60 was 102-32/B507 Silver RE paint of the type sold by CreativeMaterials, and the decorative coating 82 was 1050 HF BAC70913 topcoatsold by HSH Interplan, Inc.

In one non-limiting embodiment of the invention, the foam mount waspainted in the manner descried in PROCESS A.

Process A

-   -   1. HSH Interplan, inc. EED non-crazed cleaner for composites was        applied to the inner walls 61 of the groove 30 of the foam mount        26 with a lint free Kimberly-Clark WypAll L30 wipe followed by a        stream of low pressure compressed air to remove lint and foreign        particles from the groove 30;    -   2. 102-32/B507 Silver RF paint (hereinafter also referred to as        “Silver RF paint”) was prepared per directions provided by the        manufacturer of the Silver RF paint;    -   3. A paint stick or a swab was used to apply a layer 60 of the        Silver RF paint to the inner walls 61 of the groove 30 of the        foam mount 26 (see FIG. 3). Care was exercised not to apply any        of the Silver RF paint to the inboard inner surface 41 of the        foam mount 26.    -   4. The layer 60 of the Silver RF paint applied over the inner        walls 61 of the groove 30 was cured per instructions provided by        the manufacturer of the Silver RF paint.    -   5. After the curing of the layer 60 of the Silver RF paint on        the walls of the groove, a blank 70 (see FIG. 4) having a shape        similar to the shape of the pane 28 to be mounted in the groove        30 was provided. In one non-limited embodiment of the invention,        the blank was a cardboard blank, however, the invention is not        limited thereto, and the blank can be made of any material, e.g.        but not limited to wood, metal, glass or plastic. The thickness        of the blank 70 is not limiting to the invention, and the        thickness is preferably 80-90% of the thickness of the pane 28        to be mounted in the groove 30 of the foam mount 26 for the        reason discussed below. As mentioned above, the blank 70 has a        shape similar to the shape of the pane 28, however, in this        non-limiting embodiment of the invention, the shape of the blank        is 5-10% smaller than the shape of the pane 28 to be mounted in        the groove 30. By providing a blank 70 that is thinner and        smaller than the pane 28 to be mounted in the groove 30, the        groove 30 of the foam mount 26 is not excessively flexed when        the blank 70 was inserted in the groove 30 to partition the        inboard inner surface 36, from the outboard inner surface 38, of        the foam mount 26 to prevent coating overlap.    -   6. The layer 60 of the Silver RF paint was sprayed onto the        outboard inner surface 42, and the outboard side 50, of the foam        mount 26 (see FIG. 3). Care was taken not to spay the outer        surface 64 of the foam mount, however, overspray of the Silver        RF paint onto the outer surface 64 was noted. In this        non-limiting embodiment of the invention, overspray of the        Silver RF paint onto the outer surface 64 is acceptable.    -   7. The layer 60 of the Silver RF paint on the outboard inner        surface 42, and the outboard side 50, of the foam mount 26 was        cured per directions provided by the manufacturer of the Silver        RF paint. The blank 70 remained in the groove 30 of the foam        mount during the curing of the Silver RF paint.    -   8. After the curing of the layer 60 of the Silver RF paint on        the outboard inner surface 40, and the outboard side 50, of the        foam mount 26 was completed, the inboard inner surface 41 of the        foam mount 26 was cleaned using HSH Interplan, Inc. EED cleaner.        Thereafter, HSH Interplan, Inc 1025 primer/sealer was painted on        the inboard inner surface 41 of the foam mount 26. The sealer        was cured in one of the following manners: heated at 95°        Fahrenheit for 15 minutes or cured at room temperature for one        hour. After the sealer was cured, the layer 62 of the decorative        paint was sprayed over the sealer. Care was taken not to spay        the sealer or the decorative paint on the outer surface 64 of        the foam mount 26, however, overspray of the sealer and the        decorative paint onto the outer surface 64 was noted. In this        non-limiting embodiment of the invention, overspray of the        sealer and the decorative paint onto the outer surface 64 of the        foam mount 26 is acceptable.    -   9. The layer 62 of the decorative paint on the inboard inner        surface 41 of the foam mount 26 was cured per directions        provided by the manufacturer of the decorative paint.

The term “overspray” as used herein is defined as a coating or layerhaving a decreasing thickness as the distance from the coating areaincreases. In the practice of the invention, the overspray of the SilverRF paint has a thickness that decreases as the distance from theintersection of the outboard side 50, and the outer surface 64, of thefoam mount 26 increases (see FIG. 3), and the overspray of the Silver RFpaint terminates short of the intersection of the inboard side 44, andthe outer surface 64, of the foam mount 26. The overspray of thedecorative paint 62 has a thickness that decreases as the distance fromthe intersection of the inboard side 44, and the outer surface 64, ofthe foam mount 26 increases (see FIG. 3), and the overspray of thedecorative paint terminates short of the intersection of the outboardside 50, and the outer surface 64, of the foam mount 26. Further, theoverspray of the decorative paint and the overspray of Silver RF paintpreferably do not overlap.

After the layers or coatings applied to the foam mount were cured ordried, the blank 70 was removed and the electro chromic window 26 wasmounted in the groove 30 of the foam mount 26. The conductive layer 60on the foam mount 26 is electrically connected with the aircraft wall toconnect the electric conductive layer of the foam mount to the electricground of the aircraft. With this arrangement, the electric conductivelayers of the window 28 and the electric conductive layer 60 of the foammount 26 provide an RF shielding over the window opening in the body ofthe aircraft. Covering the walls 61 of the groove 30 of the foam mountassures that there is no break in the RE shield provided by theelectrodes 32 and 33 of the pane 28 and the electric conductive layer 60of the foam mount 26. With reference to FIG. 2, wires 72 (see FIG. 2)contacting the electrodes 32 and 33 of the pane 28 and wire 74contacting the Silver RF paint 60 were arranged in groove 76 (see FIGS.2 and 3) in the outboard side 50 of the foam mount 26 to meet at tab 78formed on outer surface 64 of the foam mount 26. The wires were providedwith connectors (not shown) to connect to the electro chromic window 28and the layer 60 of the Silver RF paint to the electrical system of theaircraft 22.

As can now be appreciated, the practice of PROCESS A does not providefor the prevention of overspray onto the outer surface 64, and theinboard side 44, of the foam mount 26 (see FIG. 3). The inventioncontemplates preventing the painting or covering the outer surface 64,and/or the inboard side 44, of the foam mount 26 with the electricconductive layer 60 and the decorative paint layer 62, respectively. Inone non-limiting embodiment of the invention, the decorative paint andthe electrically conductive paint are applied with a paint brush or witha paint roller to prevent the covering of the outer surface 64, and theinboard side 44, of the foam mount 26. In another non-limitingembodiment of the invention, the foam mount 26 is positioned in a maskdesigned to prevent or minimize the covering of the outer surface 64,and/or the inboard side 44, of the foam mount 26 with the conductivepaint and the decorative paint, respectively.

With reference to FIG. 5, there is shown a non-limiting embodiment of amask 90 of the invention to prevent or minimize the covering of theouter surface 64, and/or the inboard side 44, of the foam mount 26 withthe conductive paint and/or the decorative paint, respectively. Thecoating mask 90 includes a base 92 having a plurality of spaced uprightpins 94 secured on the base 92 in any convenient manner, and positionedon the base 92 to contain the foam mount 26 as shown in FIG. 6 and toprevent sideway motion of the foam mount 26 without compressing theouter surface 64 of the foam mount. The height of the pins 94 asmeasured from surface 96 of the base 92 of the mask 90 is equal to, orslightly greater, e.g. greater than 0 to 10% greater than the thicknessof the foam mount 26 as measured between the outboard side 50 and theinboard side 44 (see FIG. 3) to avoid compression of the foam mount 26when the mask cover 98 is positioned over the foam mount 26 and engagesthe pins 94. As can be appreciated, as the percent difference betweenthe height of the pins 92 and the thickness of the foam mount 26increases, the greater the probably of over spray of the conductivepaint and the decorative paint passing through the space between themask cover 98 and the foam mount 26, and depositing over the outsidesurface 64, and/or the inboard side 44, of the foam mount 26.

With continued reference to FIG. 5, the base (hereinafter also referredto as the “mask base”) 92 includes support plates 100 and 102. A shim104 is secured to the support plate 100 in any convenient manner, e.g.by screws or welding. One plate 106 of a hinge 108 is secured to side110 of the shim 104, and the other plate 112 of the hinge 108 is securedto outer surface 113 of the mask cover 98 at hinge support 114 (clearlyshown in FIG. 7) so that inner surface 116 of the mask cover 98 and thesurface 96 of the mask base 92 can be pivoted toward and away from oneanother to position the inner surface 116 of the mask cover 98 on thepins 94 (the mask cover 98 in the closed position as shown in FIG. 7),and to move the inner surface 116 of the mask cover 98 away from thepins 94 toward the open position (mask cover 98 shown in the openposition in FIGS. 5 and 6). Preferably, but not limiting to theinvention, the thickness of the shim 104 as measured between the innersurface 116 of the mask cover 98 and the surface 96 of the mask base 92is equal to the height of the pins 94. As is appreciated, the inventioncontemplates a solid endless or continuous wall in place of the pins 94.A piece of the sold continuous wall 119 is shown only in FIG. 5 andshown only in phantom.

With reference to FIG. 8, in one non-limiting embodiment of theinvention, one mask cover 98A is provided with a cut out center portion120 sized such that with the mask 90 in the closed position, the innersurface 116 of the mask cover 98A overlays the inboard side 44 of thefoam mount 26. With reference to FIG. 9, in the non-limiting embodimentof the invention under discussion, another mask cover 988 is providedwith a cut out center portion 120 sized such that with the mask 90 inthe dosed position, the inner surface 116 of the mask cover 988 overlaysthe outboard side 50 of the foam mount 26 adjacent the intersection ofthe outboard side 50, and the outer surface 64, of the foam mount 26 asshown in FIG. 9. As can be appreciated, when the cut out portions 120are the same size, one size mask cover 98 can be used in the practice ofthe invention.

With reference to FIGS. 5-7 as needed, the mask cover 98 furtherincludes a fastener support 120 that is aligned with the support 102 ofthe base 92 when the mask cover 98 is in the closed position (see FIG.7). The mask cover 98 is preferably maintained in the closed positionwhen the masks 90 are moved into and out of the cure chamber (notshown). The invention is not limited to the type of fastener 122 used inthe practice of the invention to maintain the mask in the closedposition. In one non-limiting embodiment of the invention, the fastenerwas a magnetic fastener 122 having magnetic bar 124 secured to thesupport plate 102 of the base 92 of the mask 90, and a magnetic bar 126secured to fastener support 120 of the mask cover 98. The positive sideof the magnetic bar 124 faces the magnetic bar 126, and the negativesurface of the magnetic bar 126 faces the magnetic bar 124. The magneticbars are secured to their respective support in any convenient manner,e.g. by screws 128 (see FIGS. 6 and 7). The thickness of the magneticbars 124 and 126 as measured between the surface 96 of the mask base 92and the inner surface 116 of the mask cover is equal to the thickness ofthe shim 104, or the height of the pins 94.

In another non-limiting embodiment of the invention, the mask 90 wasused to apply the conductive layer 60 and the decorative layer 62 toselected portions of the foam mount 26 in the manner described inPROCESS B.

Process B

-   -   A. Steps 1-5 of PROCESS A were practiced.    -   B. The foam mount 26 having the blank 70 was placed within the        pins 94 of the mask 90 (see FIG. 6) with the inboard side 44 of        the foam mount 26 on the surface 96 of the base 92 of the mask        90. The mask cover 98B was positioned in the closed position        such that the mask cover 98B overlaid a portion of the outboard        side 50 of the foam mount 26 adjacent the intersection of the        outboard side 50, and the outer surface 64, of the foam mount 26        (see FIG. 9).    -   C. The layer 60 of the Silver RF paint was sprayed onto the        outboard inner surface 42, and the uncovered portion of the        outboard side 50 of the foam mount 26 (see FIG. 9).    -   D. Step 7 of PROCESS A was practiced.    -   E. The inboard inner surface 41 of the foam mount 26 was cleaned        as described in Step 8 of PROCESS A above.    -   F. The foam mount 26 having the blank 70 was placed within the        pins 94 of the mask 90 (see FIG. 6) with the outboard side 50 of        the foam mount 26 on the surface 96 of the base 92 of the mask        90. The mask cover 98A was positioned in the closed position        such that the mask cover 98A overlaid the inboard side 44 of the        foam mount 26 (see FIG. 8).    -   G. The sealer identified in Step 8 of PROCESS A was applied over        the inboard inner surface 38 of the foam mount 26 and cured        according to Step 8 of Process A.    -   H. After the sealer was cured, the layer 62 of the decorative        paint was sprayed over the sealer to apply the decorative paint        over the inboard inner surface 38 of the foam mount 26.    -   I. Step 9 of PROCESS A was practiced.

The mask cover 98A prevented overspray of the sealer and decorativecoating 62 over the outer surface 64, and the outer surface 64, of thefoam mount 26, and the mask cover 988 prevented overspray of theconductive coating 60 over the outer surface 64 of the foam mount 26. Asis appreciate the invention is not limited to the sequence in which theinboard surfaces 44 and 50 of the foam mount 26 are painted.

After the groove 30, the inner surfaces 41 and 42, and the outboard side50, of the foam mount 28 are covered, and the conductive paint and thedecorative paint have cured, the blank 70 was removed and the electrochromic window 29 having the conductive layer 36 was mounted in thegroove 30 of the foam mount 26 as discussed above.

It is readily appreciated by those skilled in the art that modificationscan be made to the non-limiting embodiments of the invention withoutdeparting from the concepts disclosed in the foregoing description. Itis understood that various changes can be made without departing fromthe spirit of the invention as defined by the claimed subject matterwhich follows.

1. A method of applying an electric conductive layer to selectedportions of a foam mount, the foam mount in a shape having an enclosedframe surrounding an open area, the frame in cross section having aperipheral surface; an inner surface opposite to the peripheral surface,the inner surface defining the open area; a first side extending fromthe peripheral surface to first portion of the inner surface, and anopposite second side extending from the peripheral surface to secondportion of the inner surface, wherein the inner surface of the foammount includes open end of a groove and the open end of the groove facesthe open area of the foam mount, and the first portion is on one side ofthe open end of the groove and the second portion is on the other sideof the open end of the groove, comprising: applying a first electricconductive coating over inner surface of the groove; insertingperipheral edge of a substrate in the groove to completely cover theopen area of the foam mount to separate the foam mount into a firstsection and a second section, wherein the first section comprises thefirst side and the first portion, and the second half comprises thesecond side, and the second portion; applying a second electricconductive coating over the first section, wherein the coating on firstportion and the coating on the inner surface of the groove contact oneanother, and applying a non-electric conductive coating over the secondsection.
 2. A foam mount painted according to the method of claim
 1. 3.A method of making an RF shielded window, comprising: providing a foammount, the foam mount in a shape having an enclosed frame surrounding anopen area, the frame in cross section having a peripheral surface; aninner surface opposite to the peripheral surface, the inner surfacedefining the open area; a first side extending from the peripheralsurface to a first position of the inner surface, and an opposite secondside extending from the peripheral surface to a second portion of theinner surface, wherein the inner surface of the foam mount includes openend of a groove facing the open area of the foam mount and the firstportion is on one side of the open end of the groove and the secondportion is on the other side of the open end of the groove; providing atransparency having an electric conductive layer over a major surfacethe transparency, the transparency shaped and sized to fit within thegroove of the foam mount and completely cover the open area of the foammount; providing a substrate having a peripheral shape similar toperipheral shape of the transparency; applying a first electricconductive coating over inner surface of the groove; insertingperipheral edge of the substrate in the groove to completely cover theopen area of the foam mount to separate the foam mount into a firstsection and a second section, wherein the first section comprises thefirst side and the first portion, and the second half comprises thesecond side and the second portion; applying a second electricconductive coating over the first section, wherein the second coating onthe first section of the foam mount and the first coating on the innersurface of the groove contact one another; applying a non-electricconductive coating over the second section of the foam mount; removingthe substrate from the foam mount, and placing the transparency in thegroove of foam mount.
 4. An aircraft cabin window having RF shielding,the window made according to the method of claim
 3. 5. A coating maskcomprising: a base; a wall mounted on the base and extending upward fromthe base; a first shim mounted on the base between perimeter of the baseand the upright wall; a second shim mounted on the base between theperimeter of the base and the wall, the first and the second shimsspaced from on another, and a cover mounted to the first shim to move ina first direction to a closed position, wherein the cover in the closedposition is over the base and on the second shim, and to move the coverin an opposite second direction to an open position to expose the wall,wherein the cover has an opening, wherein the opening is sized such thatwhen the cover is in the dosed position, the cover overlays the wall. 6.The mask according to claim 5 wherein the wall is selected the group ofa plurality of spaced upright members, a continuous solid wall andcombinations thereof.